Spektr Group has successfully completed a large-scale Turnaround (TAR) project involving comprehensive inspection, redesign, overhaul, and recommissioning of critical industrial systems.
This massive project was executed over a 7-week period, involving more than 4,000 manhours, and covered full-scope mechanical, hydraulic, pneumatic, and electrical system rehabilitation. The objective was to restore operational integrity, eliminate long-standing technical deficiencies, modernize control systems, and ensure safe, stable, and efficient plant performance.
Full Technical Scope Delivered
The project included:
∙ Comprehensive inspection of hydraulic, pneumatic, electrical, and mechanical systems
∙ Replacement of worn and damaged hoses, components, and control elements
∙ Full cleaning and hot oil flushing of hydraulic systems
∙ Pressure testing of hydraulic and pneumatic circuits
∙ Overhaul of all electrical motors
∙ Continuity and insulation testing of electrical cabling
∙ Redesign and modernization of control systems (PLC / HMI)
∙ Full-cycle operational testing and performance verification
∙ Development of updated hydraulic, pneumatic, and electrical diagrams
Major System Upgrades & Redesign
During recommissioning, a critical hydraulic hammering issue was identified — traced back to previous system modifications performed before the turnaround.
Our engineering team conducted a full technical re-evaluation and implemented a redesign of the hydraulic system. Following modification, the system now operates reliably at maximum pressure without instability.
Additional improvements included:
∙ Complete replacement of outdated pneumatic and hydraulic control systems with modern PLC / HMI architecture
∙ Redesign of the hydraulic cooling system — converting from an ineffective water-based system to a high-efficiency air-based cooling solution
∙ Fabrication and machining of a damaged hydraulic press piston rod assembly
∙ Installation of safe access platforms and ladders for elevated equipment
∙ Preparation for full modernization of the electrical control panel
Technical Challenges Solved
This project required advanced troubleshooting and engineering intervention:
∙ Hydraulic hammer elimination through system redesign
∙ Full piston rod reconstruction via precision machining
∙ Restoration of cable inspection wells and successful electrical integrity testing
∙ Structural safety improvements for operator access
Each challenge was resolved without compromising schedule integrity or safety standards.
Operational Results
Following completion:
∙ All systems were successfully recommissioned
∙ Stable hydraulic and pneumatic pressure achieved
∙ Control systems validated under operational conditions
∙ Full production cycle tested and verified
∙ Automated pressure and temperature monitoring implemented
∙ Zero safety incidents recorded
The facility was returned to full operational readiness in stable and optimized condition.
Safety & Quality Performance
Throughout the project:
∙ Zero Lost Time Incidents (LTI)
∙ No environmental impact
∙ No quality non-conformities
∙ Full compliance with industrial safety and electrical standards
Strict toolbox talks, risk assessments, and quality control procedures were maintained daily.
Knowledge Transfer & Documentation
Comprehensive training sessions were delivered to operational and maintenance personnel, covering:
∙ PLC / HMI operation
∙ Alarm management
∙ System monitoring
∙ Troubleshooting procedures
∙ Safety functions
Complete handover documentation included:
∙ As-built hydraulic and electrical diagrams
∙ Pressure test reports
∙ Calibration certificates
∙ Operation & maintenance manuals
∙ Warranty documentation
This massive turnaround project reflects Spektr Group’s engineering capability, technical depth, and ability to execute complex system rehabilitation under demanding industrial conditions.
We are proud to deliver high-impact industrial solutions that improve safety, reliability, and long-term operational performance.
Spektr Group – Precision in Technology, Reliability in Service
